Cast Aluminium

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Guys I was at work today and was given a tiny little part off a Diesel Pump housing and it had a crack around the neck that a sensor screwed into, I have been Tig welding for about 7 years and would say im pretty experienced but as you all know there are a lot of ****ty castings out there When i started welding it it just bought a lot of black **** to the surface as you have all seen before. What I am wanting to know is what are all your tricks for welding real porous ****ty castings?
Reply:Chemical cleaning, preheat to boil the crap out and I run the tig torch over the joint before adding any filler.  This brings the stuff to the top so I can clean it again.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Thanks David, What chemicals are the best to use. I only ever use acetone on Ally. Do you recomend soaking the part in the chem?
Reply:that may be so soaked full of fuel you'll have to heat/cool/clean a few cycles to get all the crap out of the poresBill BerryKeith Berry & Son Ltd.machine work, and weldingBear River Vollunteer FD
Reply:Acetone is fine, but its "a little flammable" .  I use stuff called "Shop Kleen" by wellworth.  It works great and isn't as nasty.Heat is your friend.  It will boil the crap out better than anything else.I learned to make a pass over the aluminum with the torch here.  It draws a bunch of stuff out instead of welding it and then grinding it back off.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Yes, heat may boil out the impurities,  but it will also boil out the seals and everything else that is close to the area.  Due to the ultra fine tolerances found in an injection pump,  I would be very cautious about too much anything because the slightest amount of deformation can destroy the usability of the pump.  Of course it might not be usable in the current state, but generally fuel injection housings are generally available in sections so that you can either remove for repair or replace affected part.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT